Packaging machine



y 1963 J. NEAL ETAL 3,09

PACKAGING momma Original Filed Oct. 9, 1959 15 Sheets-Sheet l INVENTORS. MORRIS P. NEAL JAMES L. NEAL BY svLvAN v. DICE A TTORN E Y July 16, 1963 .1. NEAL ETAL PACKAGING MACHINE Original Filed Oct. 9, 1959 CASE REMOVAL STATION 2&

LOADING $TAT\0N -uup\uuc1 smmou SET-UP sun-mu? 1 15 Sheets-Sheet 2 INVENTORS. Mamas P. NEAL JAMES L. NEAL syLvAN v. cues A TTORNE Y July 16, 1963 .1. NEAL ETAL. 3,097,463

PACKAGING MACHINE Onginal Filed Oct. 9, 1959 15 Sheets-Sheet 3 INVENTORS. M02215 0. NEAL JAMES L. NEAL BY SYLVAN v. me:

ATTORNEY July 16, 1963 J. NEAL ETAL 3,097,463

PACKAGING MACHINE Onginal Filed Oct. 9, 1959 15 Sheets-Sheet 4 INVENTORS. means 9. NEAL JAMES L. NEAL SYLVAN v. once ATTORNEY July 16, 1963 J. L. NEAL ETAL 3,

PACKAGING MACHINE Onginal Filed Oct. 9, 1959 15 Sheets-Sheet 5 INVENTORS. 4a 9 MOQRIS P. NEAL E5 L. NE ENmAN V. DK!

BY fi QM A TTORNE Y July 16, 1963 J. L. NEAL ETAL 3,0 ,463

PACKAGING MACHINE Onginal Filed Oct. 9. 1959 15 Sheets-Sheet 6 INVENTORS. MORRIS P. NEAL JAMES L. NEAL B SYLVAN V. DICE A TTORNE Y July 16, 1963 J. L. NEAL ETAL 3,097,463

PACKAGING MACHINE Onginal Filed Oct. 9, 1959 15 s s 7 INVENTORS. MORQIS P. NEAL d S L. NE L 5 QI AN V. DIC E A? QM A TTORNE Y y 1963 J. L. NEAL ETAL 3,09

PACKAGING MACHINE 0n inal Filed Oct. 9, 1959 5 m '6 15 Sheets-Sheet 8 INVENTORS. MORRIS P. NEAL JAMES L. NEAL B SYLVAN V. DICE f /z. fl Z. QA/

A TTORNE Y July 16, 1963 J. NEAL ETAL PACKAGING MACHINE l5 Sheets-Sheet 9 Orxginal Filed Oct. 9, 1959 n Y m m m L 0 may July 16, 1963 J. NEAL ETAL 3,0 ,463

PACKAGING MACHINE Onginal Filed Oct. 9, 1959 15 Sheets-Sheet 10 721 BY vLvAu Di s j 452. QM

A TTORNE Y July 16, 1963 J. L. NEAL ETAL 3,097,463

PACKAGING MACHINE Onginal Filed Oct. 9, 1959 15 Sheets-Sheet l2 INVENTORS. M02215 P. NEAL mes L.NEAL sYLvAN v. one:

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ATTORNEY July 16, 1963 J. L. NEAL ETAL PACKAGING MACHINE Original Filed Oct. 9, 1959 INVENTORS.

NEAL NEAL ATTORNEY l5 Sheets-Sheet 13 MORRIS P.

JAMES L.

svwAN v. once July 16, 1963 J. L. NEAL ETAL PACKAGING MACHINE 15 Sheets-Sheet 14 Original Filed Oct. 9. 1959 2 Q; Q; 2 m a s 2 M 0 a) 5 Z 2 I. Eu 9 u 9. 3 2. P Q

5 WM m 2 M 0 I I I I n 4 q 92 W. 8 m a s w a M INVENTORS.

NEAL JAMES 1.. NEAL svwau v. mes

ATTORNEY July 16, 1963 .1. L. NEAL ETAL 3,097,463

PACKAGING MACHINE l5 Sheets-Sheet 15 Onginal Filed Oct. 9, 1959 Moams F a AL JAMES L'. NEAL BY SYLVAN v. Dice A TTORNE Y United States Patent 3,097,463 PACKAGING MACHINE James L. Neal and Morris P. Neal, Clearwater, and Sylvan V. Dice, Tarpon Springs, Fla assignors to A-B-C Packaging Machine Corporation, Clearwater, Fla, a corporation of Florida Original application Oct- 9, 1959, Ser. No. 845,442. Di-

gizdgtiwand this application Aug. 29, 1960, Ser. No.

24 Claims. (Cl. 53-186) The particular advantages of the device of our invention and the means whereby the objectives are accomplished are described below in connection with the detailed description.

The most important, outstanding and significant advantage of our machine is its extremely high rate of speed. The speed is so great that the machine can handle cases at a higher rate than cans can be fed into the machine, and can load cans into cases at a higher rate than cans can be introduced into the loading station. Therefore. it is a significant advantage of the machine and unique with respect to machines of this type that the machine has a speed which is limited only by the rate at which cans can be fed to the machine.

An object of the invention is to provide such a machine which will not fail or jam if one or more of the cartons in the pile which is fed to the machine are jammed or battered.

Another object is such a machine which operates at an especially high rate of speed with a minimum of malfunctioning.

Other objects will become apparent from the drawings and from the following detailed description in which it is intended to illustrate the applicability of the invention without thereby limiting its scope to less than that of all equivalents which will be apparent to one skilled in the art. In the drawings like reference numerals refer to like parts and:

FIGURE 1 is a partially schematic elevation of one embodiment of the machine of the invention, taken from what will be called herein, as a convention, the right hand side;

FIGURE 2 is a partially schematic plan view of the machine of FIGURE 1;

FIGURE 3 is a detailed elevation from the right hand side of the unpiling station portion of the machine of FIGURE 1;

FIGURE 4 is a partially cutaway and elevation of the portion of FIGURE 3, taken from the left end;

FIGURE 5 is a partial cross-sectional view of the portion of FIGURES 3 and 4 taken on line A-A in FIG- URE 4;

FIGURE 6 is a fragmentary cross-sectional view taken on line B-B in FIGURE 3;

FIGURE 7 is a fragmentary enlarged cutaway elevation of a portion of the drive mechanism;

FIGURE 8 is a fragmentary cross-sectional view of a modification of the embodiment of FIGURE 6;

FIGURE 9 is a fragmentary cross-sectional view of the modified embodiment of FIGURE 8 wherein the elements thereof are in a different position;

FIGURE 10 is a fragmentary detailed elevation of the 'ice setup station portion of the machine of the embodiment of FIGURE 1, taken from the lefthand side;

FIGURE 11 is a partially cutaway, cross-sectional detailed view of a portion of the embodiment of FIGURE 1 which is shown in FIGURE 10, taken on lines CC in FIGURE 10;

FIGURE 12 is a detailed cross-sectional view of one of the elements of FIGURES 10 and 11;

FIGURE 13 is an elevation corresponding to FIGURE 10, of a portion of a mechanism of FIGURE 10 showing some of the elements thereof in a different position;

FIGURE 14 is a fragmentary cross-sectional view from the same point as FIGURE 11, of a portion of a mechanism of FIGURE 11 showing some elements of FIGURE 11 in a different position;

FIGURE 15 is a detailed plan view of the loading sta tion portion of the embodiments of FIGURES 1 and 2;

FIGURE 16 is a fragmentary cutaway detailed plan view of a portion of the mechanism for operating one of the elements of FIGURE 15 taken on line DD in FIGURE 15;

FIGURE 17 is a cross-sectional detailed view of the portion of FIGURE 15 taken on line DD in FIG- URE 15;

FIGURE 18 is a cross-sectional detailed view corresponding to FIGURE 17 showing some of the elements thereof in a different position;

FIGURE 19 is a partially schematic, partially fragmentary cross-sectional view of a modified embodiment taken from the same point as FIGURE 17;

FIGURE 20 is a fragmentary, cross-sectional view corresponding to FIGURES 17, 18, and 19, showing a portion of the elements thereof in a different position;

FIGURE 21 is a schematic plan view of a modified embodiment of a portion of the loading station;

FIGURE 22 is a fragmentary cross-sectional view taken on line FF in FIGURE 21;

FIGURE 23 is a fragmentary elevation taken on line G-G in FIGURE 21;

FIGURE 24 is a fragmentary cross-sectional view of a portion of a modified embodiment of the loading station taken at about the center of the loading station;

FIGURE 25 is a fragmentary schematic cross-sectional view corresponding to FIGURE 24 showing a different position of part of the elements therein;

FIGURE 26 is a cutaway, fragmentary plan view of a modified embodiment of a portion of the loading station;

FIGURE 27 is an elevation of the modification of FIGURE 26;

FIGURE 28 is a cross-sectional view of the modification of FIGURES 26 and 27 taken on a plane corresponding to line GG in each of FIGURES 26 and 27;

FIGURE 29 is a fragmentary elevation of switching mechanism;

FIGURE 30 is a cross-sectional view taken on lines H-H in FIGURE 29;

FIGURE 31 is a fragmentary view of a portion of FIGURE 29 plus additional elements, showing change of position;

FIGURE 32 is a fragmentary view of elements from FIGURES 29 and 30; and

FIGURE 33 is a fragmentary view of elements from FIGURES 29 and 30.

For convenience, the detailed description of the machine has been divided into sections devoted to several stations. At each of the stations a carton passing through the machine is maintained stationary for a certain length of time.

The first station comprises means for maintaining a pile of cartons and feeding cartons one at a time from the pile to the next station. It has been designated the unpiling station and may also be referred to variously as the magazine" station or feeding station. The second station is referred to as the set up station" and at this station each folded carton is set up, that is, unfolded into rectangular form. It is also preferred to close two of the flaps at this station. Following the setup station, the case travels to the loading station" where cans are loaded into the case. As a final step, loaded cases are removed from the loading station and one or more additional flaps may be closed. The loaded cases may then be transported to storage areas or to other machines by any sendable method.

No means are shown for maintaining the flaps closed, as by bonding or gluing with cement or adhesive or by fastening with staples or the like, but, if desired such means may be added tothe machine or provided in a machine through which the cases may pass after leaving the machine of the invention.

The machine of the invention may be utilized in many instances to load empty cans into cases which are then not securely fastened shut but are transported to areas where the cans are filled, the cans first being removed from the cases, then filled and then reloaded into the cases whereupon the flaps of the cases are then sealed closed.

The main frame of the machine comprises right main frame member and left main frame member 10'.

The machine may be supported by tubular upright frame members 7 and tubular horizontal members 8 and held thereby in an angular position to cause cans 100 to roll or slide into the loading station by gravity.

In FIGURES 1 and 2 there are shown inclined tracks 331 down which cans 100 are fed into the machine. A part of the lowermost track 331 is a hinged plate 326 pivotally mounted on shaft 327. The plate is forced downward by the weight of cans 100 to thereby close switch 328. If there are no cans on plate 326 it is raised by the action of counterweight 329, which opens switch 328 to stop the machine, by reason of switch 328 being wired in series with a control for the main drive of the machine.

Unpiling Station At this station the machine maintains a pile of folded cartons each lying in a horizontal position and each piled one above another, removes one carton at a time from the bottom of the pile and feeds each such carton to the next station.

The frame of the magazine is provided by bars 11 and 12 which are supported by cross bars 13, the lowermost three of bars 13 being attached to and supported by main frame members 10 and 10'. Cross bars 13 are threaded to permit adjustment of the lateral spacing of bars 11 to accommodate various sizes of cartons.

To the bars 11 are attached walls 14 which hold the pile of folded cartons in lateral position. The bars 12 hold the cartons in fore or aft position.

Between frame members 10 and 10' are sprockets 15 and 16 which carry chains 17. Attached to chains 17 are lugs 18 which carry the cartons from one stage to the next along main frame members 10 and 10. A second chain 19 is mounted in a frame 20 and has lugs 21 thereon which move from stage to stage simultaneously with lugs 18. The chain 19 is driven intermittently from ratchet wheel 22 thru gear 27, pinion 28, sprocket 33, chain 34, gears 35 and 36 (which reverse the direction of rotation) and chain 37, as shown in FIGURE 1.

The intermittent movement of chain 17 is obtained by means of the ratchet wheel 22 and pawl 23 mounted on arm 24 (see FIGURES 1 and 7). Arm 24 is driven by crank 25 acting thereon, crank 25 being driven by main drive motor 29 which drives chain 3!] which passes over sprocket 31 attached to shaft 32 to which crank 25 is firmly attached. The ratchet wheel 22 drives gear 27 engaging a pinion 28 fastened to the shaft of sprocket 16.

.4 The gear ratio is 4 to i, so that 90 degree rotation of the ratchet wheel will cause one complete turn of sprocket 16.

Before lugs 18 engage a folded carton, and to make sure that only one carton is carried forward at a time, additional driving means is provided, as shown especially in FIGURE 5 and also in FIGURES 3 and 4, to select one carton and position it for the lugs to carry forward. This means comprises arm 39 and finger 40. Arm 39 is mounted on a bar 41 which is held by spring 38 downwardly against roller 42 adjustable for height by rotation of rotatable eccentric shaft 43. Bar 41 is reciprocated by arm 44 which is pivotally attached at 50 to arm 41 and pivotally mounted on fixed shaft 51. Cam follower roller 45 is attached to plate 44 and driven by cam 46 to impart motion to plate 44. Cam 46 is rotatably driven at a speed determined from that of main chains 17, by reason of drive chain 47 being driven by a sprocket mounted on the shaft on which sprocket 15 is mounted.

Arm 39 is shown in FIGURE 3 in a retracted position. Finger 40 may be wedge shaped as shown and when the arm is carried forward by the cam, as shown in FIGURE 5, finger 40 can separate the lowest carton from the carton next above at its rearward edge. Arm 39 can then carry it forward to break any adhesion between the lowest carton and next carton.

Cam 46 may be rotatably adjustable on shaft 52 in relation to sprocket 53 which is rigidly afiixed to shaft 52 and driven by the chain drive 47. Such adjustment permits timing of the drive so that the separating action of finger 40 and driving action of arm 39 take place just before the lugs 18 begin to drive the carton forward.

Folded cartons 9 may be partly supported by angle members 48 as shown in FIGURE 6, but the greater part of the weight of the pile of cartons 9 may be carried by the rollers 49 to reduce the force required to drive each bottom carton forward out from under the pile and thereby prevent damage to the edge of the cartons by the driving lugs 18.

To further reduce the force required to slide each bottom carton out from under the pile, lifting plates 60 and 60' may be placed at each side of the magazine. These plates may be fixed to bars 61 and 61' pivotally mounted in bearings 59 and 59' and can be turned by cranks 62 and 62 through an angle of 45 degrees. The plates 60 and 60' are shown in their inoperative position in FIGURE 4. In FIGURE 6 the plates are turned to their lifting position in which they lift the cartons 9 while the lowest carton is removed; then the plates are returned to the position in FIGURE 4 to allow the cartons to feed downward.

Cranks 62 and 62 may be operated by compressed air cylinders 64 which act directly against cranks 62 which in turn drive cranks 62' through links 58. The air to the cylinders may be regulated by suitable valves and cams (not shown), but driven by chain 17. The return stroke of each cylinder may be made by the action of an internal spring within each cylinder.

In the alternative method of lifting the folded cartons as shown in FIGURES 8 and 9 there may be provided at each side of the magazine a plate 65 having at its inner surface a layer of foam rubber or like spongy material 66. Plates 65 may be supported by slotted brackets 67 mounted on pins 68 carried by arms 69. Arms 69 may be fixed to shafts 70 and 71 and the upper shaft 70 may have an arm 72 connected to a cylinder 64.

When air is admitted to cylinder 64, arms 69 move plates 65 inward and upward. Arms 69 may have cylindrical surfaces 73 so that when the plates 65 reach the position shown in FIGURE 9, the plates are moved upward only, with the cylindrical surfaces 73 maintaining a constant pressure on the plates to lift the cartons. Plates 65 and brackets 67 form the connections by which the lower arms are caused to follow the movement of the upper arms, that is, serve the function of links 58 in the embodiment of FIGURES 3, 4 and 6.

Set- Up Station At this station the cases are unfolded and two of the flaps may be closed. The chains 17 carrying lugs 18 are driven by an intermittent motion which causes the cases to stop at the set-up station While these operations are performed.

The cases are formed with cutway parts to form flaps as shown at points 80 and 80 (FIGURE 13). The cases are also formed with creases at 80 and 81 so that they will hinge at these points in being set up.

To lift the end wall of the case, vacuum cups 116 are mounted on a swinging arm 117. The arm 117 is mounted on a shaft 118, the center of which is coaxial with the rear hinge point of the case when the case is carried into temporarily stationary position at the set-up station by the lugs 118.

The arm 117 and shaft 118 are carried by a bracket 119 which may be supported by frame member To operate the arm 117, a second shaft 120 may be mounted in bracket 119 and the shafts may have crank arms 122 and 121 attached respectively thereto. Link 123 may be pivotally attached to the ends of arms 121 and 122. Shaft 120 may also carry crank arm 124 having link 125 pivotally attached thereto at its outer end. The link 125 may be pivotally attached at its other end to slide bar 26 which may be supported by guiding member 127 which is provided with a series of rollers 128 to reduce friction when the bar 126 is moved by arm 129 which is provided with slot 130 which receives stud 13-1 fixed to bar 126.

Lever 129 may be securely fixed to a shaft 132 rotatably mounted in the frame and shaft 132 may be oscillated by a cam 133 mounted on a shaft 134 which is rotatably mounted in the frame so that cam 133 drives lever 135 firmly fixed to shaft 134.

The action of cam 133 through levers 135 and 129 and stud 131 may drive the bar 126 downward to swing the arm 117 and vacuum cups 116 down on to the folded carton in the position shown in FIGURE 13, acting through the linkages previously described. The downward movement of lever 129 also increases the tension in the spring 136 which has one end connected to the lever 129 and the other end connected to the frame.

Vacuum cups 116 may be connected through tubes 137 (only partly shown for simplicity) to vacuum pump 115 (FIGURE 1). By means of valve 138 whch may close and open tubes 137 vacuum cups 116 are enabled to hold or release the carton as the valve 138 is operated by cam 139 on shaft 134.

The cycle of operations is therefore: first, a case or carton 9 is carried to the position shown in FIGURES 13 and 14. The arm 116 is then brought downward so that vacuum cups 116 are pressed onto the upper surface of the case. Then valve 138 opens so that vacuum is applied to the cups. The cam 133 then releases the arm 135 and the spring 136 raises the lever 129. By means of the connecting links and levers the arm 117 is hingeably moved to the position shown in FIGURES 10 and 11 and the vacuum cups bring the upper side of the case to a vertical.

While one side of the case is being raised it is desirable to hold down the lower side of the case with vacuum cups 141 which are positioned below the case. Cups 141 are mounted on a sliding tube 142 supported by brackets 143. On the tube 142 is a block 144 provided with a stud 145. Tube 142 extends through a helical compression spring 152 which bears upwardly against the uppermost of brackets 146 and downwardly against block 144. A forked lever 146 engages the stud and the lever 146 is fixed as a crank arm to a shaft 147.

The slide bar 126 has an extension 148 carrying a lug 149. Rod 150 is pivotally connected at 146 to crank arm 151 on shaft 147 and extends slidably through lug 149. At the lower end of rod 150 are nuts positioned so that when the extension 148 is at the lowest point of travel,

the lug 149 will act thereagainst to pull rod 150 downward and thereby raise the cups 141 up firmly against the lower side of the case 9. This movement also compresses spring 152 between block 144 and upper bracket 143.

When cam 133 releases arm 135 and permits spring 136 to raise lever 129, it also allows spring 152 to force downward block 144, tube 142 and vacuum cups 141. The vacuum cups move only a small distance and hold the lower side of case 9 firmly down against the frame members 10 and 10' while the upper side is forced into set-up position by cups 116 but they preferably do not move far enough downward to break the vacuum of the cups.

After the case has been set-up to the position shown in FIGURES 10 and I1, two of the vertical flaps shown as flaps 82 and 83 may be closed by arm 153. Arm 153 may be mounted on one end 154 of a bell crank extended from shaft 156. The other end 155 of the bell crank may be connected to an air cylinder 157 by a rod 158. Shaft 156 and cylinder 157 may be supported by a frame 159 attached to frame member 10. Compressed air is admitted to cylinder 157 through tubing (not shown) extending from switch 161 to the cylinder and is controlled by a valve opened at the correct time by switch 161 which is operated by arm 162 on shaft 134.

Arm 153 is shown in retracted position in FIGURE 14. This figure also shows the arm in dotted outline in a position about halfway through its stroke. FIGURES l0 and 11 show the arm in the position of having closed the flaps.

The case is formed with upper and lower flaps shown as 84 and 85. It is desired to spread these flaps outward during at least the initial portion of the time of closing the vertical flaps 82 and 83. To lift flap 84, fingers 164 are mounted on a shaft 165 which is mounted on bracket 163 which is rotated by an am 166 and rod 167. The rod 167 is moved by an arm 168 on shaft 155. Another pair of fingers, one of which is shown at 169, is carried by shaft 155 to press down the lower flap 85. The fingers 164 and 169 are positioned so that they engage upper and lower flaps 84 and 85 and push them out of the way just before arm I53 begins to close the vertical flaps.

Shaft 134 is driven by a sprocket 110 timed to operate in conjunction with chains 17, so that the set-up operation is performed while chains 17 are not in motion.

Loading Station In FIGURES l5 and 17 a carton and cans are shown in position for loading. In FIGURE 18 part of the loading action is shown as having been completed. In FIG- URE 19 the cans are shown as having been forced fully into the carton by loading rams. In FIGURE 20 there is shown the manner in which a portion of the machine may be swung outward to permit a case to be removed.

In the modified embodiment of FIGURES 21, 22, and 23, two flaps may be plowed open as the carton is moved along the frame prior to reaching the loading station. In FIGURES 24 and 25 and also in FIGURES 26, 27 and 28 there are shown additional modified embodiments.

Referring now to FIGURES 15, 16, 17 and 18, attached to main frame members 10 and 10' there may be provided horizontal bars 213 and 214 (FIGURE 16).

Longitudinal bars 215 and 216 and 217 are supported parallel to members It} and lit by bars 213 and 214 which extend horizontally from member 10' to bar 215 and by bracket members, not shown, but attached to the frame members 10 and 10'. Two horizontal guide plates 213 and 219 extend between bar 216 and bar 217.

Carriage 221 is supported by plates 218 and 219 and can move laterally along the plates on wheels 222 above and below the plates which also serve to cause tube 220 which depends downward from the carriage, to be maintained in a vertical position. Tube 220 may also be guided at its lower end by bars 213 and 214 between which it extends.

To move the tube 220 laterally a double acting cylinder 223 is provided. The cylinder is operated by compressed air supplied to tubes 224 from air valves, not shown, but operating in conjunction with movement of the chains 17.

Cylinder 223 may rotate a vertical shaft 225 thru arm 226 firmly attached to the shaft. Fixed to the upper and lower ends of shaft 285 are arms 227 pivotally connected to links 228 and 229 which are pivotally connected to tube 220. When the cylinder is operated it therefore moves the tube 220, by means of the arms 227 and links 228 and 229, along the guide bars toward the carbon.

Furthermore, lever 211 (FIGURE 1) is operated by carton 9 to close switch 212 and thereby indicate that a carton has arrived at the loading station; switch 212 is installed as an interlock with the switch (not shown) which governs the operation of cylinder 223, so that rams 233 will not operate to drive cans into a carton unless a carton is present at the loading station to receive the cans.

The cans 100 are supported by a series of decks 231 which are the bottom surfaces or members of runways of tracks in which cans are fed to the machine. The decks form inclined planes so that the cans are fed by gravity in the direction of the arrow 101 (FIGURE Vertical tube 220 ha attached to it a series of rams 233, each of which has a wide end at 234 to push against a number of cans. The rams are spaced to fit between the decks and therefore when the tube 220 is moved thru its stroke the cans are pushed into the carton.

As shown in FIGURES 15, 17 and 18 the carton 9 has foldable vertical flaps 92 and 93 and foldable horizontal flaps 94 and 95. To make sure that these flaps are wide open and to provide a funnel for entrance of the cans to maintain correct orientation of the cans and prevent jamming, a series of hinged smooth plates are positioned at the entrance to the carton.

Two of these funnel plates 238 are attached to vertical shafts 239 which are journaled in brackets 240. Attached to carriage 221 is plate 241, to which are attached cam bars 242 and 243. The cam bars are also supported by guides 244. Shafts 239 have attached to their upper ends, cranks 2.45 which have at their ends rollers 246. Cam bars 242 and 243 have cam surfaces 247 at their ends which are adapted to move rollers 246 so that when tube 220 is moved thru the first part of its stroke, the cam bars cause shafts 239 to turn thru to This rotation of shafts 239 brings the funnel plates 238 against flaps 92 and 93 and into the carton as shown in FIGURE 18 to provide smoothly converging sides to guide the cans into the carton.

To provide a smooth entrance for the cans at the lower side of the carton plate 248 may be mounted on square horizontal shaft 249 which may be rotated by the linkage shown in FIGURE 16. Tube 220 carries a bracket 250 which is provided with a roller 251. Stud 252 on bar 213 pivotally supports slotted arm 253 and roller 251 operates in the slot of arm 253. The slot is shaped so that the first part of the stroke of the tube 220 does not operate the arm; the second part of the stroke moves the arm to the position shown in dotted lines 253 and the third part of the stroke does not move the arm. Arm 253 has attached to it arm 254. Shaft 248 has attached to it crank arm 255 which is connected to arm 254 by rod 256, one end of which is pivotally connected to arm 254 by rod 256, one end of which is pivotally connected to crank 255 at 201. Collars or blocks 203 are firmly fixed to rod 256 and collars or blocks 204 are slideably mounted thereon; interposed between collars 203 and 204 are springs 205. Arm 254 is provided at its end with an aperture through which rod 256 passes so that collars 204 are urged against opposite sides of the end of arm 254 by springs 205. When arm 253 is moved it will therefore turn shaft 249 thru 60 to 90 to bring plate 248 down 8 on fiap so that plate 248 then provides a smooth runway for the cans to slide on.

Near the upper surface of the carton may be another square shaft 257 rotatably mounted in brackets 258. Shaft 257 carries plate 259 which normally hangs in a vertical position by gravity. As the cans are forced into the carton the upper layer of cans force the plate 259 under the flap 94 to open it somewhat and assure smooth entrance of the cans.

One of the features of the machine of our invention is that it can load one layer of cans into a carton, or, by adjustment, load two layers of cans into a carton as indicated in FIGURE 18. To accomplish the latter the rams are caused to make two loading strokes while the carton remains in the position shown. The distance moved in the loading stroke by rams 233 may be the same for loading both the first and second layer of cans, the ends of the rams being approximately at line 86 which is the hinge point of the carton flaps at the end of each stroke. Accordingly, the stroke of the rams is not long enough to drive the first layer cans fully into the carton. To cause the first layer of cans to travel the remaining distance into each carton, they may be given a sufficiently high velocity by the rams that inertia carries them at least part of the remaining distance and may be provided in a housing 262 against which the carton rests to create a magnetic field which may act on the cans to cause them to travel the entire distance into the carton.

Thus, as shown in FIGURE 18 a first layer of cans 100 after being loaded into the carton may be held in place by magnets 261 while a second layer of cans 100 is being forced past the funnel plates by rams 233.

A preferred sequence of operations may thus be as follows:

A carton is carried into position by chains 17 and lugs 18 and operates lever 211 to close switch 212 (FIGURE 1) and cause the cans resting on hinged portion 326 of lowermost deck 331 to maintain switch 328 closed. The air cylinder 223 begins to move tube 220 and carrying rams 233. The cam surfaces 247 of cam bars 242 and 243 turn funnel plates 238 so that plates 238 extend into the carton and force carton flaps 92 and 93 somewhat outwardly. Shaft 249 is turned to cause plate 248 to hold down flap 95 and extend into the carton as a ramp on which the cans can travel. The cans are pushed forward by rams 233 and they force plate 259 into the position shown in FIGURE 18 to guide cans into the carton. At the end of the ram stroke rams 233 stop moving toward the carton but the cans due to their inertia continue to move into the carton.

As the cans leave rams 233 and travel into the carton, toward the closed flaps 82 and 83, they may enter the field of magnets 261 and be drawn with rapidly increasing force, as they approach the magnets, toward and against flaps 82 and 83 and may be held thereagainst by the field of said magnets acting thereupon.

After the return stroke of the rams, a second layer of cans may be fed along the inclined surfaces of the decks and into position to be carried by a second stroke of the rams into the carton. The carton is then carried away by the chains and the next carton brought into position.

Referring now to FIGURE 19 there is shown a modified embodiment wherein the rams have sufficient stroke to force the cans fully into the carton. In this case no magnets are used but a plate 263 holds the carton in position.

Magnet housing 262 or plate 263 is supported so that it can be swung out of position to permit sidewise manual removal of a case 9 from the loading station if this should be necessary due to jamming of the cans in the case or other malfunction at the loading station.

Arms 264 are attached to housing 262 or plate 263 by members 262 or 263' and are hingably supported on hinge bar 265 mounted in bracket 266. Arms 264 are normally held upright by latch 267 on pin 268. The latch can be raised and the frame swung outward as shown in FIGURE 20. Counter weight 269 may be attached to arms 264 to balance the weight of magnets 261 and housing 262 or the weight of plate 263 and thus facilitate raising the unit back to the upright position.

In FIGURES 21, 22 and 23 there is shown means for plowing outward the upper and lower horizontal flaps of the case in place of utilizing plates 248 and 259 and the mechanism for operating them. Plates 270 and 271 are supported by suitable brackets 260 which may be attached to 10'. The plates have inclined surfaces at 272 and 273 and when a case is carried along the frame by lugs 18 the horizontal flaps 94 and 95 of the case are plowed open by plates 270 and 271, which thereupon act as funnel members to direct cans into the carton. Side funnel members may be provided by plates 238 which may be operated through links 274 pivotally attached at points 275 by solenoids 276 and 277, as an alternative to being operated by cams 242 and 243.

As shown in FIGURES 24 and 25, plate 243 mounted on shaft 249 may be operated by utilizing a spring in place of the mechanism of FIGURE 16. Shaft 249 may be provided with crank arm 278 having tension spring 279 attached to the end thereof so that plate 243 is normally held upright by the action of spring 279. When cans are forced into the case as shown in FIGURE 25, plate 248 is forced by the cans toward a horizontal position and holds down the case flap 95 and provides a smooth ramp or tunneling member to guide the cans 100 into carton 9.

Referring now to FIGURES 26, 27 and 28, flaps 92, 93, 94 and 95 may be moved out of the way of entering cans by mechanism operating at both the set up station and the loading station and also between these two stations.

The forward end flap 93 is first opened to a position where it can be plowed back. This is accomplished at the set up station by an arm 281 mounted on a shaft 282 supported by the frame. Connected to the shaft 232 is an arm 283 operated by a cylinder 284, the piston of which is pivotally connected to the outer end of arm 283 at 280. Cylinder 284 may be connected to the source of air which operates air cylinder 151 to tuck in flaps 82 and 83 as shown in FIGURES l4 and 11 and cylinder 284 may thus be operated simultaneously with cylinder 157.

As the case is moved forward by chains 17 the vertical flaps 92 and 93- may then be plowed back by plates 28S and 286 and then held open by edges 299 and 380 of plates 289 and 290 until the case moves to the position where flap 93 is held open by plates 301 and 392. Horizontal flaps 94 and 95 are plowed open by inclined bars 287 and 288 and thus when the case reaches the loading position all four front flaps are open.

Vertical flaps 92 and 93 are held open as the case passes the loading station by edges 299 and 380 of movable plates 289 and 290 which prevent these flaps from returning to their previous position. Plates 239 and 290 are fixedly attached to shafts 293 and 294 which are journaled in brackets not shown and are provided with crank anms 295 and 297. These arms may be acted on by solenoids 291 and 292 through links 296 and 298, each pivotally connected at each end, to rotate shafts 293 and 294. After the case 9 is in position for loading at the loading station and before cans 100 begin to enter the case, the plates 289 and 290 are moved to the position shown by lines 289' and 290' by solenoids 291 and 292 while flaps 93 and 92 are held in open position respectively by plates 301 and 362 and by plates 285 and 286.

In FIGURES 29, 30, 31 and 32 and 33 there is shown means whereby rams 233 may be caused to operate either once or twice while a case is at the loading station to load respectively either one layer of cans or two layers of cans into the case. The mechanism comprises switches 313 and 314; switch 313 is operated by three-lobed cam 315 and switch 314 is operated by six-lobed cam 316. The cams are mounted firmly on cam shaft 317 turned by ratchet wheel 318 which is mounted thereon and driven by pawl 319 which is pivotally attached to lever 320; lever 320 is rotatably mounted to rotate around the axis of shaft 317 and restrained from such rotation by tension spring 323 attached to one end thereof. On one end of lever 320 is a roller 321 operated by a cam 322 mounted on the cam bar 242, which moves with the stroke of the loading rams 233. When the cam 322 is in the position shown in FIGURE 31 (at one extreme of the stroke of bar 242) the spring 323 has turned lever 32! and pawl 319 to a new position. The position of the elements at the other end of the stroke of ram 233 and bar 242 is shown in FIGURE 29 and during the stroke of ram 233 and bar 242, while roller 321 is operated by earn 322 to move lever 321, pawl 319 turns the ratchet wheel and cams 60 degrees, so that at each stroke cam 316 omrates switch 314 but Switch 313 is operated only every second stroke. Either switch may be placed in circuit with the chain driving means by switches not shown. With switch 314 in circuit the case is moved forward after each ram stroke. With switch 313 in circuit the case is moved forward after every second ram stroke.

The speed of the machine of our invention is accomplished by the action in combination of nearly all of its elements rather than by an essential or critical single element or concept in the machine and the many factors and elements hereinbefore described contribute toward achieving such speed.

These contributions can be divided into two categories, the first category being those elements and inter-relationships which contribute toward accomplishing high speed when nothing is awry, for example, when all of the cases in the magazine meet every spccification as to shape and size and have not been battered or otherwise damaged in shipping, when the cans themselves are undamaged and unbattered and do not turn sidewise or otherwise get out of position in the tracks (the tracks being of conventional prior art form) and when every element in the machine does its job just as it is supposed to do, for example, when no vacuum cup misses its grip, when lugs 18 and finger 40 do not fail to separate one and only one carton from the pile, when flaps of the carton are closed in the proper way and at the proper time, when no can turns sidewise as it is loaded into the carton, etc. Thus, speed is accomplished by providing elements which cooperating in combination provide high speed when no such malfunction occurs. Secondly, a high speed is provided when the elements cooperate in combination with an absolute and extreme minimum of malfunction on the part of any one element.

But the second category consists of reducing to a minimum the time which may be lost as a result of interruption of the process due to jamming or other malfunction and the damage caused to cans, cases or machine when any such malfunctioning occurs.

It may be seen from the foregoing detailed description that the cooperation of elements 18, 49 and finger 40 and its driving mechanism at the unpiling station uniquely operate to separate one and only one carton from the pile and feed it to the next station in the machine even when the cartons have been damaged badly in shipping, as for example is the case when a stack of cartons are strapped with steel strapping and then dropped heavily so that the strapping bites deeply into the edges, or when a stack of cartons strapped with steel strapping is dropped from the height onto a corner of the stack. These elements of the magazine and feeding station also cooperate to feed a carton from the pile to the next station when only one, two or three cartons remain in the pile and this achievement is especially outstanding when it is observed that this is accomplished even though such one, two or three remaining cartons are badly damaged. 

1. IN A MACHINE OF THE TYPE DESCRIBED FOR REMOVING FLAT, COLLASPED CARTONS FROM A PILE, SETTING THEM UP AND FILLING THEM WITH CONTAINERS AT A LOADING STATION, THE COMBINATION OF MEANS FOR PROVIDING FLAT, COLLAPSED CARTONS IN A PILE SO THAT THE WEIGHT OF THE PILE IS ON THE LOWERMOST CARTON, A FIRST MEMBER EGAGEABLE WITH THE LOWERMOST CARTON, MEANS TO MOVE SAID FIRST MEMBER SUBSTANTIALLY PARALLEL TO THE FLAT SURFACES OF SAID CARTON TO SLIDABLY REMOVE SAID CARTON FROM UNDER SAID PILE AND MEANS TO AT THE SAME TIME RESTRAIN THE PILE FROM LIKE MOVEMENT, ROLLER MEANS TO CAUSE THE UNDERSIDE OF SAID LOWERMOST CARTON TO UNDERGO ROLLING FRICTION RATHER THAN SLIDING FRICTION WHILE REMOVING SAID LOWERMOST CARTON FROM UNDER SAID PILE, AT LEAST ONE ADDTIONAL AND SEPARATE MEMBER ENGAGEABLE WITH SAID LOWERMOST CARTON AT NEARLY THE SAME TIME IT IS ENGAGED BY SAID FIRST MEMBER, TO MOVE SAID CARTON FOR A SHORT DISTANCE IN A DIRECTON AT LEAST NEARLY PARALLEL TO THE DIRECTION OF TRAVEL OF SAID CARTON TO AID IN SEPARATING SAID CARTON FROM SAID PILE AND A PLURALITY OF LIFTING MEMBERS TO ENGAGE THE SIDE OF SAID PILE TO AT LEAST PARTIALLY LIFT A PORTION OF THE WEIGHT OF SAID PILE FROM SAID LOWERMOST CARTON WHILE SAID LOWERMOST CARTON IS SLIDABLY REMOVED FROM UNDER SAID PILE. 